|
Enter cylinder No. for reassembly on the side of the connecting rod big end.
|
|
Special tool Piston pin setting tool (MD998780) consists of parts shown in the illustration.
Use also special tool Guide D (MB991659) to remove the piston pin.
|
|
1.Insert the push rod into the piston pin from the front mark side of the
piston top surface, and attach special tool Guide D (MB991659).
2.Set the piston and connecting rod assembly on the base so that the front mark of the
piston faces upward.
3.Use a press to push the push rod and pull out the piston pin.
| note |
After pulling out the piston pin, organize pistons, piston pins and connecting rods by
cylinder No.
|
|
|
1.When replacing a piston, check the cylinder bore size mark stamped on the illustrated
position of the cylinder block and select a corresponding piston from the table below.
|
|
Cylinder bore size mark
|
Piston size mark
|
A
|
A
|
B
|
B or None
|
C
|
C
|
|
| note |
The piston size mark is indicated on the piston top face.
|
2.Insert the push rod into the piston pin and attach guide A.
3.Align the front mark of the piston with that of the connecting rod to assemble.
4.Apply engine oil to the circumference of the piston pin.
5.Insert the guide A side of the piston pin assembled in section 1 into the pin hole
from the front mark side of the piston.
|
|
6.Screw guide B into guide A and open clearance between guide A and guide B by 3 mm (make
the base in line with flushed surface) to assemble.
7.Set the piston on special tool piston setting base so that its front mark faces upward.
8.Use a press to press fit the piston pin. If the press fit load is below the standard
value, replace the piston pin (piston assembly) or connecting rod, or both.
Standard value: 7,500 - 17,500 N
|
|
1.Assemble the spacer of the oil ring into the piston ring groove. Then, assemble the upper
side rail, and after this assemble the lower side rail.
| note |
Install the side rail and end gap of the spacer so that they are at the position as shown
in the illustration.
|
|
|
2.| caution |
The side rail may be broken if its end gap is widened
by a ring expander as in other piston rings.
|
When assembling the side rail, push it by fingers, after fitting one end of the side rail
into the piston groove, for easy assembly.
3.After assembling the oil ring into the piston, make sure that the side rail turns
smoothly to either direction.
|
|
Use a piston ring expander to assemble piston rings with their identification marks facing
upward. Piston rings can be assembled by hand without using the piston ring expander.
Identification mark:
No. 1 ring: 1T
No. 2 ring: 2T
|
|
|
1.Apply a sufficient amount of engine oil to the circumference of the piston, piston
rings and oil ring.
|
|
2.Arrange end gap positions of piston rings and oil ring (side rail and spacer) as shown
in the illustration.
3.Insert the piston and connecting rod assembly from the top surface of the cylinder
block with the front mark of the piston top face facing toward the timing belt side.
|
|
4.| caution |
Driving it in hard causes breakage of piston rings and damage
to the crank pin.
|
Firmly tighten the piston ring with a ring band and insert the piston and connecting rod
assembly.
|
|
|
1.When replacing a connecting rod bearing, select the bearing corresponding to the crankshaft
pin outside diameter according to the crankshaft pin identification in the table below.
|
|
Crankshaft pin
|
Connecting rod bearing
|
Identification mark
|
Journal diameter mm
|
Identification mark
|
1
|
47.966 - 47.972
|
1
|
2
|
47.960 - 47.966
|
2
|
3
|
47.954 - 47.960
|
3
|
|
|
|
2.An identification mark of a crankshaft is stamped at the illustrated position by No.
|
|
3.A connecting rod bearing has an identification mark at the illustrated position.
|
|
1.| note |
The connecting rod resulting from the breaking process has the high insertion force. The
new connecting rod assembly may possibly be difficult to remove the connecting rod.
If difficult to remove it, alternately strike the two bolt heads with a plastic hammer
while the connecting rod bolt is slightly loosened, or strike the centre of the cap shaft’s inside
diameter slightly and outward.
If the outside of the cap is directly struck, the lateral force is added to the broken-out
section. Thus, pay attention to the broken-out section that might be difficult to be separated
or might fall.
Clean the broken-out section before the installation to the engine, using compression
air.
|
Assemble the bearing cap on the connecting rod by aligning it with the mark put during
removal. If a new connecting rod without a mating mark is used, assemble so that the detent notch
of the bearing is on the same side as illustrated.
|
|
2.Make sure that clearance of the thrust of the connecting rod big end is appropriate.
Standard value: 0.10 - 0.25 mm
Limit: 0.4 mm
|
|
1.Check in the following procedure before reusing the connecting rod bolt.
(1)
Measure the outside diameter "A."
(2)
Measure the smallest outside diameter "B" within the range "X" shown in the illustration.
(3)
If the difference of outside diameter of thread exceeds the limit, replace the connecting
rod bolt.
Limit: 0.1 mm
2.Apply engine oil to the threaded portion and seat surface of the bolt before installing
it.
3.After installing each bolt and tightening it by fingers, tighten bolts alternately
to properly assemble the cap.
4.Tighten the bolt in several steps until the torque reaches 5.0 N·m.
5.Tighten the bolt in several steps until the torque reaches 20 N·m.
|
|
6.Put a paint mark on the bolt head as illustrated.
7.Put a paint mark on the connecting rod at 90° position in the tightening
direction of the bolt with reference to the paint mark position of the bolt.
8.| caution |
- When the tightening angle is smaller than the specified tightening
angle, the appropriate tightening capacity cannot be secured.
- When the tightening angle is larger than the specified tightening angle, remove
the bolt to start from the beginning again according to the procedure.
|
Tighten the bolt 90°, and make sure that the paint mark of the connecting rod
is aligned with that of the bolt.
|
